Asymmetric consumables for a plasma arc torch

Patent metadata

Field	Value
Publication number	US-10314155-B2
Application number	US-201715832154-A
Country	US
Kind code	B2
Filing date	Dec 5, 2017
Priority date	Aug 6, 2012
Publication date	Jun 4, 2019
Grant date	Jun 4, 2019

Abstract

A torch tip assembly of a plasma arc torch is provided for delivering a diffused stream of plasma arc in a gouging operation. The assembly comprises a nozzle including a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end. A nozzle exit orifice of the nozzle body defines at least a bore for conducting the plasma arc therethrough. The assembly also comprises a counter bore feature, disposed relative to the distal end the nozzle body, fluidly connected to the bore and located distally relative to the bore. At least one of the bore or the counter bore feature has a non-circular cross-sectional shape in a plane perpendicular to the longitudinal axis. The non-circular cross-sectional shape is configured to enable a second non-circular cross-sectional shape in the plasma arc that diffuses the plasma arc.

First claim

What is claimed is:

1. A torch tip assembly of a plasma arc torch for delivering a diffused stream of plasma arc to a workpiece to perform a gouging operation, the assembly comprising:
a nozzle including (i) a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end, (ii) a chamber in the nozzle body for receiving an electrode at the proximal end, and (iii) a nozzle exit orifice at the distal end of the nozzle body, the nozzle exit orifice defining at least a bore for conducting the plasma arc therethrough, the bore being disposed distally relative to the chamber, the bore having a first cross-sectional shape in a plane parallel to the longitudinal axis and a second cross-sectional shape in a plane perpendicular to the longitudinal axis; and
a counter bore being fluidly connected to the chamber via the bore that is between the counter bore and the chamber, the counter bore located along the central longitudinal axis, the counter bore having a first cross-sectional shape in the plane parallel to the longitudinal axis and a second cross-sectional shape in the plane perpendicular to the longitudinal axis, the first cross-sectional shape of the counter bore being substantially rectangular;
wherein at least one of the second cross-sectional shape of the bore or the second cross-sectional shape of the counter bore is non-circular, the at least one second non-circular cross-sectional shape of the bore or counter bore configured to facilitate a non-circular cross-sectional shape of the plasma arc adapted to diffuse the plasma arc in the workpiece; and
wherein an area of the second cross-sectional shape of the counter bore at a proximal end of the counter bore is greater than an area of the second cross-sectional shape of the bore at a distal end of the bore.

2. The assembly of claim 1 , wherein the counter bore, defined by the nozzle exit orifice, is disposed in the nozzle.

3. The assembly of claim 1 , wherein one of the second cross-sectional shape of the bore or the counter bore is circular.

4. The assembly of claim 1 , wherein the second non-circular cross-sectional shape of the bore or counter bore is one of an ellipse, a trapezoid, a slot, a rectangle, a triangle or tri-lobed.

5. The assembly of claim 1 , wherein the plane perpendicular to the longitudinal axis is defined by a first transversal axis and a second transversal axis perpendicular to each other, the at least one non-circular second cross-sectional shape of the bore or counter bore having a first length along the first transversal axis that is different from a second length along the second transversal axis.

6. The assembly of claim 1 , wherein the nozzle further defines a set of gas passages disposed about the bore.

7. The assembly of claim 6 , wherein the set of gas passages are disposed in a non-circular pattern about the bore.

8. The assembly of claim 1 , wherein the counter bore is disposed on a shield connected to the nozzle and defined by a shield exit orifice of the shield.

9. The assembly of claim 8 , wherein at least one of the bore or the counterpart bore is positioned at a specific radial orientation relative to the longitudinal axis for orienting the at least one second non-circular cross-sectional shape of the bore or counter bore to directional disperse the plasma arc.

10. The assembly of claim 8 , wherein at least one of the nozzle or the shield includes a clocking feature for positioning and securing the bore or the counter bore at the specific radial orientation.

11. The assembly of claim 1 , wherein the plasma arc is adapted to form a gouge profile in the workpiece with a width to depth ratio of greater than 3 to 1.

12. The assembly of claim 1 , wherein the non-circular cross-sectional shape of the plasma arc is elliptical.

13. The assembly of claim 12 , wherein a major axis of the elliptical cross-section shape of the plasma arc is oriented substantially perpendicular to a direction of a gouge path in the workpiece.

14. The assembly of claim 5 , wherein the non-circular cross-sectional shape of the diffused plasma arc has a first length along the first transversal axis that is different from a second length along the second transversal axis.

15. A torch tip assembly of a plasma arc torch for delivering a diffused stream of plasma arc to a workpiece to perform a gouging operation, the assembly comprising:
a nozzle including (i) a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end, (ii) a chamber in the nozzle body for receiving an electrode at the proximal end, and (iii) a nozzle exit orifice at the distal end of the nozzle body, the nozzle exit orifice defining at least a bore for conducting the plasma arc therethrough, the bore being disposed distally relative to the chamber, the bore having a first cross-sectional shape in a plane parallel to the longitudinal axis and a second cross-sectional shape in a plane perpendicular to the longitudinal axis;
a shield with a shield exit orifice defining at least a counter bore feature being fluidly connected to the chamber of the nozzle via the bore of the nozzle, the counter bore feature located along the central longitudinal axis, the counter bore feature having a first cross-sectional shape in the plane parallel to the longitudinal axis and a second cross-sectional shape in the plane perpendicular to the longitudinal axis;
wherein at least one of the second cross-sectional shape of the bore or the second cross-sectional shape of the counter bore feature is non-circular, the at least one second non-circular cross-sectional shape of the bore or counter bore feature configured to facilitate a non-circular cross-sectional shape of the plasma arc that diffuses the plasma arc in the workpiece; and
wherein an area of the second cross-sectional shape of the counter bore feature at a proximal end of the counter bore feature is greater than an area of the second cross-sectional shape of the bore at a distal end of the bore.

16. The torch tip assembly of claim 15 , wherein the plane perpendicular to the longitudinal axis is defined by a first transversal axis and a second transversal axis perpendicular to each other, the non-circular cross-sectional shape of the diffused plasma arc having a first length along the first transversal axis that is different from a second length along the second transversal axis.

Assignees

• Hypertherm Inc

Inventors

• Patel Shreyansh
• Darrow Clifford G
• Agan David
• Moody Steven
• Higgens Martin
• Shipulski E Michael

Classifications

• B23K9/0135 Primary

  Arc saw cutting · CPC title

• B23K10/00 Primary

  Welding or cutting by means of a plasma · CPC title

• H05H1/3423

  Connecting means, e.g. electrical connecting means or fluid connections · CPC title

• H05H1/34 Primary

  Details, e.g. electrodes, nozzles · CPC title

• H05H2001/3463

  Electricity · mapped topic